Method of producing a shear resistant captive screw

ABSTRACT

A CAPTIVE SCREW INCLUDING A SLEEVE HAVING A BORE SUBSTANTIALLY COMPLEMENTARILY RECEIVING A RELATIVELY LARGE DIAMETER PORTION OF THE SHANK OF A SCREW INWARDLY OF THE SCREW HEAD, WITH AN ANNULAR ENLARGEMENT ON THE SHANK, OF GREATER FIAMETER THAN THE BORE, BEING LOCATED AT THE END OF DHIS SHANK PORTION AND RETAINING THE SCREW OT THE SLEEVE. BEYOND THE ANNULAR ENLARGEMENT, THE SHANK IS PROVIDED WITH AN ANNULAR GROVE AND ROLLED THREADS ON ITS OUTER END. THE SLEEVE INCLUDES A HEAD AT ONE END AND AN ENLARGED BOER PORTION AT THE OPPOSITE END PROVIDING A RELATIVELY THIN WALL ADAPTED TO BENT OUTWARDLY TO SECURE THE SLEEVE TO A WORKPIECE. THE FASTENER IS PRODUCED BY FIRST PROVIDING A SCREW BLANK HAVING A HEAD AND PORTIONS OF TWO DIAMETERS, THE LARGER DIAMETER PORTION BEING EXTENDED THROUGH THE SLEEVE, FOLLOWING WHICH DIES ARE ENGAGED WITH THE BLANK AT THE JUNCTURE OF THE SMALLER AND LARGER DIAMETER PORTIONS, PRODUCING AN ANNULAR GROOVE AND DISPLACING MATERIAL OUTWARDLY INTO RECESSES IN THE DIES WHERE THE ANNULAR ENLARGEMENT IS SHAPED. A BULGE ON THE SMALLER DIAMETER PORTION OF THE SHANK ALSO IS CREATED WHEN THE GROOVE IS FORMED, WHICH THEN IS GROUND OFF, AFTER WHICH THREADS ARE ROLLED ON THE END PORTION OF THE SHANK.

Oct. 26, 1971 GULISTAN 3,614,799

METHOD OF PRODUCING A SHEAR RESISTANT CAPTIVE SCREW Filed July 14, 1969 2 Sheets-Sheet iL IINVENTOR BULENT GULISTAN ATTORNEYS B- GULISTAN Oct. 26, 1971 2 Shoctu-5311e0t 2 Filed July 14 1969 FIG. 7

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N A b, T 1 A S R m m Z. m w 4 m m m m w w m Y B 9 3 1M 3 3 a 6 mm 4 4 .I.\|7 W 2 4 4 4 2 3 4 4 4 T T I a 8 2 z /4 m O B 2 O l 2 4 Q I 2 4 m E F United States Patent 3,614,799 METHOD OF PRODUCING A SHEAR RESISTANT CAPTIVE SCREW Bulent Gulistan, Malibu, Calif., assignor to Deutsch Fastener Corp., Los Angeles, Calif. Filed July 14, 1969, Ser. No. 841,325 Int. Cl. B231) 19/08; B21h 3/02; 1B23g 9/00 US. Cl. 10-155 14 Claims ABSTRACT OF THE DISCLOSURE A captive screw including a sleeve having 'a bore substantially complementarily receiving a relatively large diameter portion of the shank of a screw inwardly of the screw head, with an annular enlargement on the shank, of greater diameter than the bore, being located at the end of this shank portion and retaining the screw to the sleeve. Beyond the annular enlargement, the shank is provided with an annular grove and rolled threads on its outer end. The sleeve includes a head at one end and an enlarged bore portion at the opposite end providing a relatively thin wall adapted to be bent outwardly to secure the sleeve to a workpiece. The fastener is produced by first providing a screw blank having a head and portions of two diameters, the larger diameter portion being extended through the sleeve, following which dies are engaged with the blank at the juncture of the smaller and larger diameter portions, producing an annular groove and displacing material outwardly into recesses in the dies where the annular enlargement is shaped. A bulge on the smaller diameter portion of the shank also is created when the groove is formed, which then is ground off, after which threads are rolled on the end portion of the shank.

BACKGROUND OF THE INVENTION The field of the invention This invention relates to a captive screw.

The prior art Captive screws, which normally include threaded elements retained by sleeves which can be attached to a workpiece, oifer significant advantages, which has led to their use in a variety of situations. Typically, captive screws are used for aircraft panels that serve as access doors for maintenance and repair. When captive screws are held to the panel, they are always instantly available for securing the panel in place when it is to be reattached. This saves time and, therefore, expense. Also, in the event that the panel is to be secured by fasteners of different sizes, it assures that the proper screw is at each location. If captive screws are not used, the panel fasteners frequently become lost when the panel is removed. This hecomes a significant item when the fasteners must be made of titanium or other costly materials. Additionally, when conventional fasteners of hard material are repeatedly moved through the openings in a panel of softer material such as aluminum, wear takes place and the openings may become too large. This would be avoided by the use of a captive screw because its sleeve acts as a bearing for the stud that passes through it, so that the moving element does not touch the panel and cannot enlarge the opening in it.

Despite these advantages, however, it has been impossible to use captive screws in many places because of their inability to withstand loads in shear. In producing fasteners with a screw slidable to a sleeve, prior designs have completely sacrificed an ability to carry shear loads.

Bfildflfi Patented (lot. 26, 19711 The present invention provides an improved captive screw which is capable of withstanding high loads in shear. The fastener includes a sleeve having a bore through which the shank of the screw extends. The shank includes a first portion within the sleeve bore that is substantially complementary to the bore of the sleeve and results in the shear capabilities for the fastener. At the end of this portion of the bore is an annular enlargement providing a shoulder that retains the screw to the sleeve. Beyond the annular enlargement is a groove, outwardly of which on the end portion of the shank are rolled threads.

The portion of the shank that is within the bore of the sleeve is of relatively large diameter for added strength, so that the diameter of this part of the shank is greater than the major diameter of the threads on the end of the shank. Consequently, the annular enlargement is required for retaining the screw to the sleeve.

The sleeve has a head at one and a second bore portion of larger diameter at the opposite end. The result is a relatively thin wall at the opposite end which can be bent outwardly for cooperating with the head in securing the sleeve toa workpiece.

In producing the captive screw, the screw blank first is formed to provide a head, beyond which is a shank portion of a first diameter connecting through a tapered shoulder, to an end portion of smaller diameter. With the sleeve prepared to have a bore substantially complementary to the first portion of the shank, it is fitted over the shank so that the end portion of the first part of the shank projects beyond the sleeve. Then, opposed dies are brought to bear against the shank to produce the annular enlargement. These dies have convex ar-cuate portions that engage the smaller diameter portion adjacent the tapered shoulder. The dies also have recesses that confine the material displaced outwardly in one direction by the arcuate die portions and define the dimensions of the annular enlargement that is produced. In forcing the material outwardly for the annular enlargement, the convex portions of the dies create an annular groove. They also cause some enlargement of the smaller diameter portion of the shank adjacent the groove, and this part is then removed to provide the outer end of the shank with a uniform dimension and the pitch diameter of the threads that are to be produced. Next is the thread-rolling operation, which completes the fastener. It is attached to a workpiece by fitting the sleeve through an opening in the workpiece, so that the thin-walled end portion projects outwardly beyond the end of the opening. Then, the thin-walled portion is bent outwardly to define a finage which holds the sleeve and, therefore, the screw to the workpiece.

An object of this invention is to provide an arrangement for a captive screw having resistance to shear loads.

Another object of this invention. is to provide a method and means for retaining a screw to a sleeve.

Yet another object of this invention is to provide an arrangement for holding a screw to a sleeve without the use of extra parts which can become dislodged and allow the screw to become separated from the sleeve.

These and other objects will become apparent from the following detailed description taken in connection with the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is an exploded side elevational view, partially in section, illustrating the screw blank and sleeve used in producing a captive screw in accordance with this invention;

FIG. 2 is an end elevational view of the head of the screw blank;

FIG. 3 is a perspective view of a die used in producing the annular enlargement to hold the screw to the sleeve;

FIG. 4 is a longitudinal sectional view, partially in elevation, showing the application of the opposed dies in the rolling operation for producing the annular enlargement;

FIG. 5 is a view similar to FIG. 4, with the annular enenlargement completed;

FIG. 6 is an elevational view showing the removal of the bulge produced on the smaller diameter portion of the shank as the annular enlargement is produced;

FIG. 7 is an elevational view showing the rolling of the threads on the end portion of the shank;

FIG. 8 is a longitudinal sectional view, partially in elevation, of the completed captive screw;

FIG. 9 is a longitudinal sectional view, partially in elevation, showing the attachment of the captive screw to a workpiece; and

FIG. 10 is a longitudinal sectional view, partially in elevation, showing the workpiece to which the screw is attached secured by the screw to a second workpiece.

DESCRIPTION OF THE PREFERRED EMBODIMENT In obtaining the captive screw of this invention, there are first prepared a screw blank 10 and a sleeve 11, as seen in FIGS. 1 and 2. The screw blank 10 may be produced by cold heading, following which it is heat treated and then preferably ground to relatively close tolerances. The blank 10 includes a head 12 provided with a suitable driving recess 13'. In the embodiment illustrated, the head 12 is of frustoconical configuration to provide a flush head installation. Extending outwardly from the head 12 is a shank that includes a first portion .14 adjacent the head which is of larger diameter than the outer portion at the distal end of the shank. The latter part of the shank is made to a diameter corresponding to the pitch diameter of the threads which later are to be formed on it. A shoulder 16, tapered toward the outer end of the shank, connects the larger portion 14 of the shank to the outer portion 15 of smaller diameter.

The sleeve 11 includes a head portion 18 having a frustoconical undersurface 19 in order that it can fit within a complementary recess in a part to which the sleeve later is attached. The head 18 also includes a frustoconical inner surface 20, which is complementary to the undersurface of the head 12 of the blank 10. The sleeve 11 includes a first bore 21 adjacent the head 18, which is dimensioned to make a sliding, close-tolerance fit with the larger shank portion 14 of the blank 10. Beyond the bore 21 is a larger end bore 22 which provides the sleeve with an end portion 23 having a relatively thin wall and a shoulder 24 between the two bores. The sleeve is made shorter than the length of the shank portion 14 of larger diameter.

The blank 10 then is inserted into the sleeve 11, as shown in FIG. 3, so that the larger portion 14 of the shank fits within the opening 21 of the sleeve. Also, the head 12 of the blank 10 is brought into adjacency with the surface of the head 18 of the sleeve. In this relative position of the blank 10 and sleeve 11, the outer part of the blank portion 14 projects beyond the end of the sleeve.

With the sleeve 11 on the blank 10 in this manner, the shank is then engaged by opposed dies 25, being rolled between them to receive the contour of the dies. This step is similar to a thread-rolling operation. The dies 25, as seen in FIG. 3, are elongated members, each of which includes a first flat surface 26 along one side. This flat surface connects, through a shoulder 27 at right angles to it, with a second flat surface 28. The flat surface 28 is parallel to the surface 27 and recessed beneath it. Beyond the surface 28, at the opposite side of the die 25, is a projecting portion 29 which has an arcuate outer contour defined by a cylindrical segment.

The dies are forced inwardly against the blank 10 at a position where the junctions between the flat surfaces 28 and the arcuate portions 29 of the dies are adjacent the end of the larger diameter portion 14 of the shank. Therefore, when the dies are pressed inwardly, the arcuate portions 29 engage the inner part of the smaller diameter end portion 15 of the shank. The arcuate portions 29, therefore, displace the material of the shank, giving it the contour shown in FIGS. 5 and 6. This produces a groove 31 in the inner part of the end portion 15 of the shank.

Some of the material displaced when the groove 31 is produced results in a bulged portion 32, outwardly of the groove, where the diameter of the shank portion 15 is increased locally. Additional portions of the material of the blank are forced outwardly in the other direction into the recesses in the dies. This material is confined and shaped by the inner flat surfaces 28 of the dies, as well as the die shoulders 27. The result is an outwardly projecting annular portion 33 at the end of the shank portion 14, which is of predetermined size as established by the contours of the dies 25. Thus, the height, width and shape of the annular segment 33 are controlled by the configuration and dimensions of the die surfaces 27 and 28, and the portion 33 is given a cylindrical circumferential surface.

The annular part 33 thus produced connects to the remainder of the shank portion 14 by a generally radial shoulder 34, and it is of greater outside diameter than the diameter of the bore portion 21 of the sleeve '11. Consequently, this permanently retains the sleeve 11 on the blank 10, as the shank no longer can be pulled through the sleeve 11. The shoulder 34 of the blank 10 will engage the shoulder 24 between the bore sections 21 and 22 to prevent such movement. The blank 10 may move a limited distance axially relative to the sleeve 11 as determined by the length of the sleeve bore 21 and the spacing between the shoulder 34 and the head 12- of the blank.

After the blank 10 has been shaped in this manner by the dies 25, the bulge 32 is removed. This may be accomplished suitably by a grinding wheel 36, which brings the entire portion of the shank 15 beyond the groove 31 to a constant exterior diameter that corresponds to the pitch diameter of the threads to be formed (see FIG. 6).

After this, the shank portion 15 is engaged between a pair of conventional thread-rolling dies 38, as shown in FIG. 7, producing threads 39 on the end of the shank. This provides the completed fastener ready to be attached to a workpiece.

The resulting captive screw then is secured to a work piece, such as the panel 40 shown in FIG. 9. The panel 40 is provided with an opening 41 dimensioned to receive the cylindrical outer portion of the sleeve 11, having a countersink 42 at one end for engagement by the undersurface 19 of the head 18 of the sleeve. The panel 40 and sleeve 11 are proportioned so that the thin-walled end portion 23 of the sleeve then projects beyond the panel surface 43 at the end of the opening 41 opposite the countersink 42. The outer part of the thin-walled portion 23 then is bent over the surface 43 of the panel 40, as indicated in phantom in FIG. 9, producing a flange 44 at the outer end of the sleeve 11. This flange 44 cooperates with the head 18 in attaching the sleeve 11 to the panel 40. This, in turn, secures the screw to the panel 40, with freedom for limited axial movement relative to the panel.

The captive screw then may be used in securing the panel 40 to another part, as indicated in FIG. 10. Here, the panel 40 is shown connected to a member 46 having a bore 47 through which the shank of the screw extends. The bore 47 includes a recessed portion 48 at one end providing clearance for the flange 44. The shank extends beyond the opening 47 to enter a conventional counterbored nut plate 49 which the threads 39 engage. Therefore, the screw, through the nut plate 49 and the sleeve 11, secures the panel 40 to the member 46.

The resulting connection will withstand high loads in shear. This is because there is a relatively large diameter portion of the shank of the screw that extends substantially complementarily through the smaller bore portion 21 of the sleeve 11. This provides the shank of the screw with added material and an ability to withstand loads in shear which can be transmitted through the sleeve lll to the closely fitting shank. Unlike conventional captive screws, therefore, the arrangement of this invention provides substantial shear strength and can be used for structural applications.

-I claim:

1. The method of producing a captive screw comprising the steps of preparing a sleeve with a cylindrical bore,

providing a screw blank with a head, and a shank projecting from said head,

with said shank being longer and of no greater diameter than said bore,

inserting said shank into said bore so that said head is adjacent one end of said bore and the distal end portion of said shank extends outwardly beyond the opposite end of said bore,

then forming a groove in said shank intermediate said distal end portion of said shank and said opposite end of said bore so as to produce a first annular enlargement on said shank on the side of said groove adjacent said sleeve with said first annular enlargement having a diameter greater than the diameter of said bore,

for thereby retaining said blank to said sleeve, and a second annular enlargement on said shank on the side of said groove remote from said sleeve, removing said second annular enlargement so as to return said shank substantially to its original diameter at the location of said second annular enlargement, and then forming threads on said shank outwardly of said groove.

2. The method as recited in claim 1 in which for forming said groove at least one member is pressed radially inwardly against said shank so as to displace material outwardly adjacent thereto for thereby producing said annular enlargements.

3. The method as recited in claim 2 including the step of providing said one member with a recess, and in which said material displaced outwardly on said side of said groove adjacent said sleeve is forced into said recess and confined on all sides therein for defining the contour of said first annular enlargement.

4. The method as recited in claim 3 in which said recess is contoured to provide said first annular enlargement with a substantially cylindrical circumferential wall, and a substantially radial edge adjacent said head.

5. The method of preparing a shear-resistant captive screw comprising the steps of preparing a sleeve with a cylindrical bore,

providing a screw blank with a head, and a shank projecting from said head such that said shank has a first portion adjacent said head and axially longer than said sleeve, with said first portion being substantially complementary to said bore,

and a second portion at the distal end of said shank of a smaller diameter than said first portion,

inserting said shank into said sleeve so that said first portion is received in said bore and extends outwardly therefrom beyond one end of said sleeve, forming a plurality of die members with outwardly projecting portions and recesses adjacent thereto, rolling said shank between said die members so that said outwardly projecting portions form a groove adjacent the juncture of said first and second portions of said shank and displace material of said shank outwardly into said recesses where said mate rial is confined on all sides by said dies to produce an annular enlargement of predetermined size and shape on said first portion, with said annular enlargement having a diameter greater than the diameter of said bore, for thereby retaining said blank to said sleeve,

and forming threads on said second portion of said shank. 6 The method as recited in claim 5 in which said outwardly projecting portion of each of said die members is provided with a convex arcuate contour,

and in which said convex arcuate portions are brought to bear against said second portion of said shank adjacent the end of said first portion of said shank and form said groove with a concave arcuate contour.

7. The method as recited in claim 5 in which in forming said groove an additional annular enlargement is formed on a portion of said second portion of said shank, and including the step of removing said additional enlargement prior to forming said threads so as to provide said second portion of said shank with a uniform exterior diameter.

8. The method as recited in claim 7 in which said additional annular enlargement is removed by grinding.

9. The method as recited in claim 5 in which said threads are formed by rolling said second portion between dies.

10. The method as recited in claim 5 in which said blank is provided with a tapered shoulder interconnecting said first portion and said second portion of said shank prior to said forming of said groove.

11. The method as recited in claim 5 in which said sleeve adjacent said annular enlargement is provided with an enlarged bore and a relatively thin wall,

and in which said sleeve is attached to a workpiece by inserting said sleeve through an opening in said workpiece so that said thin-walled portion projects outwardly therefrom on one side thereof, and said thin walled portion then is bent outwardly to overlap said workpiece adjacent said opening for holding said sleeve to said workpiece.

12. The method as recited in claim 5 in which said second portion of said shank, prior to said forming of said threads, is given a diameter corresponding to the pitch diameter of said threads.

13. The method as recited in claim 5 in which said first portion of said shank, prior to said forming of said threads, is given a diameter greater than the major diameter of said shank.

14. The method as recited in claim 7 in which said threads are formed on the full length of said second portion of said shank from the distal end thereof to said groove.

References Cited UNITED STATES PATENTS 2,192,322 3/1940 Mitchell 210-10 2,276,049 3/1942 Leighton 10-455 2,283,494 5/1942 Erdman 10 2,303,224 11/1942 Olson 10-155 3,389,736 6/1968 Gulistan 151-69 FOREIGN PATENTS 1,144,087 5/1955 Germany 10-155 CHARLES W. LANHAM, Primary Examiner E. M. COMBS, Assistant Examiner US. Cl. X.R. 151-69 

